How Mumbai metro uses ETAP Digital Twin and operator training simulator (OTS) to ensure maintenance efficiency

Everyone knows that untrained operators can make errors. But with the help of ETAP, we are building a dynamic power model. Based on the app switching sequence and the validated app switching sequence, the operator can run the EOTS and train himself.
By Mr. Sushil Ojha, Assistant General Manager ETAP India

Mumbai Metro Rail Corporation (MMRC) deployed ETAP’s Operator Training Simulator (OTS) to provide a realistic and immersive platform for operator training, switching validation, and maintenance planning. Using real-time data, historical data and simulated scenarios, OTS creates a Digital Twin of the electrical network, enabling operators to practice normal, abnormal and emergency situations safely - reducing human error and improving system availability.

The Mumbai Metro Rail Corporation Limited, known by its acronym MMRC, is an unlisted public company incorporated on 30 April 2008. It is classified as a state government company in Mumbai City, Maharashtra. It manages the Mumbai Metro Line-3 project. MML-3 has been envisioned as the modern transport of the 21st century. State-of-the-art technologies would be harnessed during the project's construction to ensure the protection of existing building structures.

Location: Mumbai, Maharashtra, India

Year: 2022

Real-time operator training simulator for maintenances department

Challenges

  • Reducing risks of human error during complex switching operations in an urban metro system
  • Training unexperienced operators on both routine and emergency sequences
  • Replicating real-world SCADA/HMI behaviour with full electrical intelligence
  • Validating startup/shutdown sequences under all operating conditions, including loading variations, disturbances, trips and islanding events
  • Ensuring safe operation while new operators learn without affecting live systems

Which solutions did they choose?

Selected applications

 

ETAP Operator Training Simulator (OTS)

  • Uses the complete ETAP Digital Twin model
  • Integrates real-time field data, historical data and simulated data
  • Mirrors customer’s SCADA/HMI screens to create a virtual control room identical to the live environment

ETAP SCADA Integration (via OPC UA & OPC DA)

  • Receives real-time field measurements from Schneider PSO SCADA
  • Sends simulated states back to trainer and trainee consoles

ETAP Real-Time Applications

  • Load Flow, Short-Circuit, Transient Stability and Switching Sequence Validation support OTS scenarios

Why do they use ETAP?

Main customer benefits

Digital Twin identical to the real control room

OTS reproduces the customer’s SCADA/HMI exactly. Operators train on the same interface they use every day - with identical alarms, breaker commands, status indications and event logs.

Three data sources for powerful scenario training

  • Real-Time Data from field devices
  • Historical Data from past operations or incidents
  • Simulated Data from ETAP electrical studies

→ enabling comprehensive “what-if” scenarios and fault playback.

Safe validation of switching actions

If a fault exists or a bus is de-energized, OTS will block breaker closing, simulating real protection behaviour - preventing unsafe operations during training.

Accelerated training & competency development

Operators practice sequences, abnormal events, load changes, islanding, synchronization, tripping and recovery in a risk-free environment.

Reduced operational costs through simulation instead of hardware testing

OTS replaces many SIL/HIL test requirements and eliminates the need for dedicated hardware environments, reducing project cost and complexity.

Improved maintenance efficiency

Switching actions can be validated using the Digital Twin before execution, lowering outage risk and improving overall reliability.

 

Conclusion

Through the combination of Digital Twin modelling, real-time integration, SCADA replication and predictive simulation, ETAP OTS enables MMRC to:
  • Train operators quickly and safely
  • Validate switching sequences before execution
  • Reduce human error
  • Ensure more efficient and reliable metro operation
MMRC now benefits from a scalable and future-ready training ecosystem aligned with its long-term operational strategy.

What do they think about ETAP?

Customer perspectives

With ETAP OTS, we are building a dynamic power model. Based on the validated app-proof switching sequence, the operator can run the EOTS and train himself.
OTS provides a complete replica of the control room with SIL environment, predictive simulation, and evaluation tools to validate every switching action before operation.

By Mr. Sushil Ojha, Assistant General Manager ETAP India



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